Production Capabilities

Flambeau Medical is your outsourcing solution for components, sub-assemblies and complete products for the healthcare industry. Our core competencies in injection molding and blow molding along with decorating, assembling and packaging make it possible for us to deliver fully packaged finished goods ready for sale. What sets us apart from other plastic manufacturers is our dedication to transparency, keeping you our customer up to date through the development and production of your product.

Molds, Tooling and Automation

Flambeau has two tool rooms (Wisconsin and Arizona) that build both injection molds and blow molds. Our shops have more than 40 year experience in building all types of tooling from quick aluminum prototype and pilot production molds to Class 101 tools for high volume precision injection and blow molding. Close tolerance tooling and fixtures for molded medical components are produced using state of the art CNC Machining, Wire EDM and Sinker EDM equipment. We also have partners in Asia and Europe that can support low cost tooling options when time is not a factor.

Our automation department has a full range of capabilities from simple fixtures to complex work centers that can drill, tap, cut, weld, assemble and test components and products. Barcoding can be integrated into the work center or as a stand-alone system in compliance with APQP and manufacturing process instructions. Flambeau Technologies Tool Group will design and build discrete equipment for product validation, functional testing and destructive testing.

Packaging

Packaging has been a core competency of Flambeau for decades. We offer a full range of disposable and sustainable packaging solutions including stock cases, totes and trays for Cardio, Orthopedic, Spinal, In Vivo and Surgical components, instruments and devices. Our custom packaging solutions can be configured for your specific application.

Injection Molding

Corporate wide, we have more than 175 injection molding machines ranging in clamping force from 30 – 1,775 Tons. Our machines are meticulously maintained with an ERP integrated Preventative Maintenance system to ensure maximum performance. We operate both hydraulic and electric presses with robotic systems for part removal, trimming and assembly. Our Class 8 molding environment use state of the art electric presses that are less than five years old. We are experienced in the full spectrum of molding materials including PEEK, PVC, Ultem, Polyesters, POM, PPS, PPO, PES, PAS, PC, Nylon, TPE, Olefins and other commodity resins.

Blow Molding

Corporate wide, we have more than 50 blow molding machines ranging in shot capacity from 1 – 50 lbs. We operate both continuous extrusion and intermittent extrusion equipment. Our machines are meticulously maintained with an ERP integrated Preventative Maintenance system to ensure maximum performance. For medical applications, we have draped presses and portable clean rooms to provide a clean molding environment for part production. We are experienced with a wide range of blow molding materials including HDPE, PP, ABS, PVC, PPO, Polyester, TPE and Nylon.

New Product Developement

We can assist with developing concepts/ideas into products using our support teams that have expertise in Industrial Design, Part Design, and Design for Manufacture as it relates to repeatable processing in a variety of manufacturing methods. We have experience with predicate devices in the industry and best-in-class methods of manufacturing and designing to protect or strengthen Intellectual Property.

Medical Device Assembly

In order to manage the ever increasing regulatory requirements placed on medical device companies, many OEM’s seek single source providers. Flambeau Medical can be your single source provider, not only manufacturing components, but assembling the equipment and packaging it. We understand the need for fully qualified processes as soon as proof-of-concept prototypes are complete.

Our creative approach to assembly and automation results not only in higher levels of statistical quality, but smaller batches and lower costs. We develop systems that are scalable and flexible enough to work with rapidly changing demands. Our modular approach to automation and our in-house design and development teams understand the rigorous demands and functional requirements for high volume/high speed assembly.

Flambeau can serve as a Tier 1 supplier by managing the entire supply chain for you. Our Quality Management System is focused on safety, reliability, compliance and documentation regardless of the role we play in the supply chain continuum. The same regulatory support is provided whether you are looking for single components, full assemblies or complete pack-out and distribution.

Product Commercialization

Flambeau also has resources available to help with product commercialization. With access to US, European, and Asian markets, we can provide product testing and submission of clinical data for CE Marking, 510k approval, or even PMA submissions. We are also closely linked to other valuable resources including clinical research organizations and several large distribution channels, both in the US and abroad. If we do not have certain resources you are looking for, we will work together to find the solution.